Mounting bracket

ABSTRACT

A bracket is provided for use in installing door hardware on a support surface. The bracket comprises a rigid member having a longitudinal axis, a front surface, a substantially planar rear surface for engaging the support surface, and a peripheral edge extending between and joining the front and rear surfaces. A spirit bubble level is disposed on the rigid member such that the rigid member can be oriented relative to a horizontal line or a vertical line, the level having the bubble centered only when the level is horizontal or vertical. At least a portion of the peripheral edge of the rigid member provides a mounting surface for the door hardware when the rigid member is secured to the support surface.

BACKGROUND

A mounting bracket is described and, more particularly, a mountingbracket for installing door hardware, such as a door operator, andensuring that the door hardware is properly positioned.

Mounting brackets are known for mounting objects, such as shelves,picture frames, mirrors, and the like, to a wall, door or other supportstructure. When mounting an object, one or more factors such as thepositioning, orientation, etc., of the object are typically evaluated todetermine a desirable or acceptable location. Conventional mountingsystems may incorporate alignment mechanisms. For example, it issometimes important that the mounted object is level, which may bedesirable for aesthetics as well as the proper functioning of theobject. It is known to integrate a spirit or bubble type level with amounting bracket for facilitating level mounting of the bracket to astructure. However, the size of the level, or the size of the componentsintegral with the bracket for holding the level, may result in having toprovide additional space to accommodate the level or the othercomponents.

Door hardware is mounted on or adjacent to a door or in a door frame,and, in the case of a door operator, effects movement of the doorrelative to the frame between a closed position and an open position. Atypical door operator includes an electric motor and a linkage assemblyfor operatively coupling the drive shaft of the motor to the door sothat the door will be opened and closed when the drive shaft rotates.The door may be closed under power or with a door closer. A conventionaldoor closer uses an internal spring mechanism which is compressed duringthe opening of the door for storing sufficient energy so that the doorcan be returned to the closed position without the input of additionalelectrical energy.

A door operator typically includes a substantially flat rectilinear backplate. When installing the door operator, the back plate is initiallysecured to the upper edge of the door using mounting bolts or otherfasteners such that the back plate extends generally horizontally. Insome applications, the back plate is mounted directly to the door frame,to the wall adjacent the door frame, or concealed within the wall ordoor frame. The components of the door operator such as, for example,the motor, the door closer, and the like, are fixed directly orindirectly to the back plate.

Templates are sometimes provided to permit a user when installing a backplate to mark the position of fastener holes to be made in the supportstructure. For a door operator mounted to a door, the template ispositioned on the door and aligned with an edge of the door. Indicia onthe template indicate where holes are to be drilled. Unfortunately,conventional templates provide no means for ensuring that the back platewill be horizontal. Other tools are necessary to level the template,although many installers merely eyeball the orientation of the template.Consequently, relatively elaborate drill jigs are available along withthe templates to aid in installing door operators. Moreover, the backplate itself is a substantial component, usually made of heavy gaugemetal for providing the necessary structural support for the dooroperator, making the back plate difficult to manipulate duringinstallation. As a result, the installation of the door operator oftenis a time consuming process that can require numerous adjustments orremounting of the hardware.

For the foregoing reasons there is a need for a new mounting bracket.The mounting bracket should be useful for mounting door hardware, suchas a door operator. Ideally the mounting bracket will function to aid auser in installing the door operator in a proper position and, ifdesired, a level or plumb orientation.

SUMMARY

A bracket is provided for use in installing door hardware on a supportsurface. The bracket comprises a rigid member having a longitudinalaxis, a front surface, a substantially planar rear surface for engagingthe support surface, and a peripheral edge extending between and joiningthe front and rear surfaces. A spirit bubble level is disposed on therigid member such that the rigid member can be oriented relative to ahorizontal line or a vertical line, the level having the bubble centeredonly when the level is horizontal or vertical. At least a portion of theperipheral edge of the rigid member provides a mounting surface for thedoor hardware when the rigid member is secured to the support surface.

A combination is provided comprising a door hardware member including abase member, and a bracket for use in installing the door hardwaremember on a support surface. The bracket comprises a rigid member havinga longitudinal axis, a front surface, a substantially planar rearsurface for engaging the support surface, and a peripheral edgeextending between and joining the front and rear surfaces. A spiritbubble level is disposed on the rigid member such that the rigid membercan be oriented relative to a horizontal line or a vertical line, thelevel having the bubble centered only when the level is horizontal orvertical. At least a portion of the peripheral edge of the rigid memberprovides a mounting surface for engaging the base member when the rigidmember is secured to the support surface, and wherein the base member ismounted properly relative to the horizontal or vertical line.

A method is also provided for installing door hardware to a surface. Theinstallation method comprises the steps of providing a bracket, thebracket including a rigid member having a longitudinal axis, a frontsurface, a substantially planar rear surface for engaging the supportsurface, and a peripheral edge extending between and joining the frontand rear surfaces, and a spirit bubble level disposed on the rigidmember. The rigid member is positioned on the surface relative to ahorizontal line or a vertical line, the level having the bubble centeredonly when the level is horizontal or vertical, and the bracket issecured to the surface. A door hardware member is provided, including abase member. The base member is positioned against the surface incontiguous relation with the bracket, wherein at least a portion of theedge of the rigid member provides a mounting surface for the base memberwhen the rigid member is secured to the support surface, and the basemember is secured to the surface.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of a mounting bracket as describedherein, reference should now be had to the embodiments shown in theaccompanying drawings and described below. In the drawings:

FIG. 1 is a front perspective view of an embodiment of a bracket for usein mounting door hardware to a support structure.

FIG. 2 is a rear perspective view of the bracket as shown in FIG. 1.

FIG. 3 is a partially exploded perspective view of the bracket as shownin FIG. 1 secured to a door and an embodiment of a back plate formounting to the door.

FIG. 4 is a close-up perspective view of an opening in the back platefor receiving the bracket as shown in FIG. 1.

FIG. 5 is a partially exploded perspective view of the bracket and backplate as shown in FIG. 3 and an embodiment of a door operator formounting to the back plate.

FIG. 6 is a side elevation cross-section view of the bracket and theback plate mounted on a door taken along line 6-6 of FIG. 5.

FIG. 7 is a perspective view of another embodiment of a bracket for usein mounting door hardware to a support structure.

FIG. 8 is a rear perspective view of the bracket as shown in FIG. 7.

FIG. 9 is a cut-off perspective view of the bracket as shown in FIG. 7and an embodiment of a door operator including a back plate secured to adoor.

FIG. 10 is a close-up perspective view of an opening in the back platefor receiving the bracket as shown in FIG. 7.

FIG. 11 is a side elevation cross-section view of the bracket and thedoor operator taken along line 11-11 of FIG. 9.

DESCRIPTION

Certain terminology is used herein for convenience only and is not to betaken as a limitation on the invention. For example, words such as“upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,”and “downward” merely describe the configuration shown in the FIGs.Indeed, the components may be oriented in any direction and theterminology, therefore, should be understood as encompassing suchvariations unless specified otherwise.

Referring now to the drawings, wherein like reference numerals designatecorresponding or similar elements throughout the several views, anembodiment of a mounting bracket for door hardware is shown in FIGS. 1and 2 and is generally designated at 20. The bracket 20 is asubstantially planar plate member, including a front major surface 22,an opposed rear major surface 24, and a peripheral top edge 32 and abottom edge 33 joined by side edges 34. The bracket 20 has a firstopening 26 and a second opening 28 adjacent the respective side edges 34of the bracket 20. In the embodiment shown, the first and secondopenings 26, 28 are generally circular holes for receiving fasteners.The first and second openings 26, 28 may be provided in a countersunkconfiguration so that an end of a fastener, such as a nail or a screw,is flush with the front surface 22 of the bracket 20 when mounted. Therear surface 24 (FIG. 2) of the bracket 20 is configured for engagingwith the surface of the support structure, which is generally flat. Acontinuous shoulder 30 is formed along the top edge 32 and the sideedges 34 of the bracket 20.

The embodiments of the bracket 20, 80 described herein are preferablyformed from metal, such as steel or aluminum, as a one-piece unitarymember. The bracket 20 may also be injection molded from a plasticmaterial, such as polycarbonate, although other conventionalthermoplastic or thermoset resins could be used. Other types ofmaterials may also be used to construct the bracket 20 including, forexample, rubber, composite materials, or combinations thereof. In oneembodiment, the material will allow the bracket 20 to be transparent. Itis understood that the scope of the invention is not intended to belimited by the materials listed here, but may be carried out using anymaterial which allows the construction and operation of the mountingbracket 20 described herein.

A level 40 is mounted on the front surface 22 of the bracket 20 suchthat the level 40 is in view of a user installing the bracket. The level40 may be a conventional level, for example, a spirit or bubble level,as shown, for insuring that the bracket 20 is level from end-to-end wheninstalled. The level 40 may be permanently or removably secured to thebracket 20. For example, the level 40 may be attached by an epoxyadhesive to the front surface 22 of the bracket 20. In the embodimentshown, opposed housings 42 integral with the bracket 20 protrude fromthe front surface 22 of the bracket 20 for securing the level 40 inplace. The mounting bracket 20 is configured such that a portion of thelevel 40 and housings extend beyond the planar front surface 22 of thebracket. In another embodiment, the level may be embedded in the bracket20.

It is understood that, although the mounting bracket 20 will bedescribed in detail herein with reference to the exemplary embodiment ofa bracket for mounting of door hardware, the mounting bracket may beapplied to, and find utility in, mounting of other objects to a supportstructure. As described above, mounting brackets are used in a widevariety of applications involving other objects such as, for example,shelves, mirrors, picture frames, fixtures, sconces and the like, ondifferent support structures, such as doors, walls, moveable panels,etc., and the like. Further, although the mounting bracket will bedescribed in detail herein as embodied in a door operator, wherein thebracket locates and supports a back plate, it is not intended to be solimited. The mounting bracket may be used in other door hardware, suchas door closers, exit devices, and the like. Thus, the mounting brackethas general applicability to any object mounted to a support structure,wherein improvements in efficiency of installation are desired.

Referring to FIG. 3, the mounting bracket 20 is shown in place on a door48 in a door frame 49, along with a back plate 50 for mounting doorhardware. The door 48 is a left-hand swinging door shown in a fullyclosed position. It is understood that the mounting bracket 20 may beused with a right-hand door since only reversal of some of thecomponents adapts the bracket to a right-hand door. The bracket 20 islocated a desired distance from a top edge and a hinged edge of the door48. The proper location of the bracket 20 may vary depending on the doorhardware to be mounted. As seen in FIG. 3, the back plate 50 is asubstantially planar elongated plate member which, as shown, isconventional other than a generally rectangular recess 52 formed in thelower edge 54 of the back plate 50 for receiving the bracket 20.Referring to FIG. 4, an inwardly extending lip 56 is formed along thetop edge 58 and side edges 60 of the recess 52. The size and shape ofthe recess 52 are configured to correspond to the size and shape of theperiphery of the bracket 20. The complementary shape relationshipprovides support, as well as a “self-aligning” or “self-centering”function when the back plate 50 is engaged with the mounting bracket 20.

In use, the mounting bracket 20 is held in a preferred position on thedoor 48 with one hand and oriented until the bubble in the tube of thelevel 40 indicates that the bracket 20 is level. In one embodiment, therear surface 24 of the mounting bracket 20 may be provided withadhesive, such as double-sided tape, to keep the bracket 20 fromslipping on the door while in place. When the level 40 is horizontal,the other hand of the user traces or scribes the shape of the bracket 20and the first and second openings 26, 28 onto the door 48 with, forexample, a pen, pencil or other marking device. In one embodiment, thehousings 42 protrude from the front surface 22 of the bracket 20 by adistance sufficient to permit the user to grip the bracket 20, such asbetween a thumb and a forefinger of one hand, for positioning thebracket 20 on the door 48 while tracing the outline of the bracket 20and the openings 26, 28. Once marks are made on the door 48, the bracket20 may be removed and holes drilled for inserting fasteners. Themounting bracket 20 is then attached to the door using, for example,screws attached to the door 48 through the first and second openings 26,28 and tightened to secure the bracket 20 to the door 48.

The back plate 50 is then placed against the door 48 and positioned onand supported by the bracket 20 (FIG. 5). Referring to FIG. 6, with themounting bracket 20 secured in a level orientation to the door 48, therear surface 24, the shoulder, the top edge and the side edges of thebracket 20 and the door 48 define a slot for receiving the lip 56 on theback plate 50. As the back plate 50 is slid down onto the bracket 20,the bracket 20 is received in the recess 52 in the back plate 50 (FIG.5) and the lip 56 on the back plate 50 is received between the bracket20 and the door 48 (FIG. 4) such that the lip sits on the shoulder 30and the back plate 50 seats flush against the door 48. Because themounting bracket 20 is mounted level, the back plate 50 will extendgenerally horizontally on the door 48 surface. The back plate 50 issecurely mounted to the door 48 using fasteners, such as screws orbolts.

As shown in FIG. 5, the remaining hardware of the door operator is thensecured to the back plate. Only a cover 64 and a linkage assembly 66 foroperably coupling the door operator to the door are shown. The cover 64serves to surround and enclose the components of the door operator toreduce dirt and dust contamination, and to provide a more aestheticallypleasing appearance. It is understood that the door hardware internal tothe cover 64 may comprise, for example, a motor assembly, a door closerassembly, a controller, and the like. Although the mounting bracket 20and the back plate 50 are shown mounted directly to the door 48, theycould be mounted to the door frame 49 or to the wall adjacent the doorframe, or concealed within the wall or door frame. Concealed dooroperators are well known in the art of automatic door operators.

A second embodiment of a mounting bracket for door hardware is shown inFIGS. 7 and 8 and generally designated at 80. The bracket 80 of thisembodiment comprises a substantially planar elongated portion 82,including a front major surface 84 and an opposed rear major surface 86,and peripheral top edges 89, 91. The planar portion 82 of the bracket 80terminates in a first ear 85 and a second ear 87 adjacent the respectiveends of the bracket 80. The ears 85, 87 define a first opening 90 and asecond opening 92 for receiving fasteners. As in the first embodimentdescribed herein, the first and second openings 90, 92 may be providedin a countersunk configuration so that a fastener, such that an end of anail or a screw, is flush with the front surface 84 of the bracket 80when mounted. A flange 88 extends upwardly from along the peripheral topedge of the planar portion 82 of the bracket 80 intermediate of the ears85, 87. The flange 88 is generally “S”-shaped in transversecross-section, extending from a planar leg extending angularly outwardlya first distance and terminating in a longitudinal edge. The flange 88is integral with the longitudinal edge of the leg, and includes a planarfirst portion extending upwardly from the leg and terminating in alongitudinal edge, the first portion of the flange and the leg defininga rear longitudinal channel 94, a planar second portion extendingangularly rearwardly a second distance from the longitudinal edge of thefirst portion and terminating in a longitudinal edge, the first distancebeing greater than the second distance, and a planar third portionextending angularly outwardly from the longitudinal edge of the secondportion of the flange. The level 40 (FIG. 7) is mounted on the frontsurface 84 of the planar portion 82 of the bracket 80, as in the firstembodiment. The rear surface 86 (FIG. 8) of the planar portion 82 of thebracket 80 is configured for engaging with the surface of the supportstructure.

Referring to FIG. 9, the mounting bracket 80 and door hardware are shownin place on a support structure, such as a door 48. The mounting bracket80 is secured to the door in a level orientation to the door asdescribed above using, for example, screws attached to the door 48through the first and second openings 90, 92 and tightened to secure thebracket 80 to the door 48. As shown in FIG. 10, the back plate 50defines a generally rectangular recess 96 formed in the lower edge 54 ofthe back plate 50 for receiving the bracket 80. The shape and size ofthe corners of the recess 96 are configured to correspond to theperiphery of the ears 85, 87 and a first planar portion extendinginwardly from the ears along the top edge of the bracket 80. The backplate 50 also has a longitudinal slot 98 spaced from the recess 96 forreceiving the upper end of the flange 88. The complementary shapedrelationship of the recess 96 to the ends of the bracket 80 provides a“self-aligning” or “self-centering” function when the back plate 50 isengaged with the mounting bracket 80.

Referring to FIGS. 9 and 11, the upper end of the flange 88 is shown inthe slot 98 in the back plate 50. A portion of the back plate below theslot is disposed in the channel 94 behind the flange 88. The flange 88may be resiliently movable with respect to the planar part of thebracket 80 such that contact with the back plate 50 may forcibly flexthe flange 88 outwardly during installation. The upper edge of thebracket 80 defines recesses adjacent the flange 88 for providingrelative flexibility of the bracket 80 and the flange 88. In use, theflange 88 “snaps” into place in the slot 98 when the back plate 50 is inthe proper position relative to the bracket 80. In this position,because the mounting bracket 80 may be mounted level, the back plate 50and door hardware will extend generally horizontally on the door 48surface.

It is understood that a plurality of levels may be disposed on thebracket for orienting the bracket during installation. In oneembodiment, two spirit bubble levels are provided and positioned suchthat they mutually perpendicular. Accordingly, the bracket may beoriented such that one level is horizontal or and the other level isvertical when the respective bubbles are centered.

Although the present invention has been shown and described inconsiderable detail with respect to only a few exemplary embodimentsthereof, it should be understood by those skilled in the art that we donot intend to limit the invention to the embodiments since variousmodifications, omissions and additions may be made to the disclosedembodiments without materially departing from the novel teachings andadvantages of the invention, particularly in light of the foregoingteachings. For example, the mounting bracket may be used to mountobjects other than door hardware to support structure other than a dooror door frame. Accordingly, we intend to cover all such modifications,omission, additions and equivalents as may be included within the spiritand scope of the invention as defined by the following claims. In theclaims, means-plus-function clauses are intended to cover the structuresdescribed herein as performing the recited function and not onlystructural equivalents but also equivalent structures. Thus, although anail and a screw may not be structural equivalents in that a nailemploys a cylindrical surface to secure wooden parts together, whereas ascrew employs a helical surface, in the environment of fastening woodenparts, a nail and a screw may be equivalent structures.

We claim:
 1. A bracket for use in installing door hardware on a supportsurface, the door hardware including a back plate for mounting doorhardware components, the back plate defining an opening in a peripheraledge of the back plate, the bracket comprising: a rigid member having alongitudinal axis, a front surface, a substantially planar rear surfacefor engaging the support surface, and a peripheral edge extendingbetween and joining the front and rear surfaces, the rigid memberadapted to be secured to the support surface; and a spirit bubble leveldisposed on the rigid member such that the rigid member can be orientedrelative to a horizontal line or a vertical line, the level having thebubble centered only when the level is horizontal or vertical, whereinthe shape of at least a portion of the peripheral edge of the rigidmember is adapted to correspond to the shape of the opening in theperipheral edge of the back plate for inserting the at least a portionof the peripheral edge of the rigid member in the opening of the backplate when the rigid member is secured to the support surface such thatat least a portion of the peripheral edge of the rigid member provides amounting surface for engaging the back plate and securing the back platerelative to the horizontal and the vertical line, and wherein theperipheral edge of the rigid member providing the mounting surface isbeveled inwardly from the front surface to the rear surface.
 2. Abracket as recited in claim 1, wherein the shape of the rigid member issubstantially rectangular.
 3. A bracket as recited in claim 2, whereinthe corners of the peripheral edge of the rigid member are rounded.
 4. Abracket as recited in claim 1, wherein the level is mounted on the frontsurface of the rigid member.
 5. A bracket as recited in claim 1, whereinthe rigid member defines fastener openings for receiving fasteners forsecuring the rigid member to the support surface.
 6. A bracket asrecited in claim 1, wherein the mounting surface is parallel to thelevel such that the mounting surface is horizontal or vertical when thebubble is centered.
 7. A bracket as recited in claim 6, wherein sideperipheral edges of the rigid member are perpendicular to the mountingsurface such that side edges are vertical or horizontal when the bubbleis centered.
 8. A bracket as recited in claim 1, further comprising ashoulder on the rear surface of the rigid member adjacent the peripheraledge, the shoulder providing the mounting surface.
 9. In combination: adoor having a surface; a door hardware member including a back plate formounting door hardware components, the back plate defining an opening ina peripheral edge of the back plate; and a bracket for use in installingthe back plate on the door surface, the bracket comprising a rigidmember having a longitudinal axis, a front surface, a substantiallyplanar rear surface for engaging the support surface, and a peripheraledge extending between and joining the front and rear surfaces, therigid member configured to be secured to the door surface, and a spiritbubble level disposed on the rigid member such that the rigid member canbe oriented relative to a horizontal line or a vertical line, the levelhaving the bubble centered only when the level is horizontal orvertical, wherein the shape of the opening in the peripheral edge of theback plate corresponds to the shape of at least a portion of theperipheral edge of the rigid member for receiving the at least a portionof the peripheral edge of the rigid member when the rigid member issecured to the door surface such that at least a portion of theperipheral edge of the rigid member provides a mounting surface forengaging the back plate and securing the back plate relative to thehorizontal and the vertical line.
 10. The combination as recited inclaim 9, wherein the shape of the rigid member is substantiallyrectangular, and wherein the shape of the opening in the peripheral edgeof the back plate is rectangular and corresponds in size to the rigidmember.
 11. The combination as recited in claim 10, wherein the cornersof the peripheral edge of the rigid member are rounded.
 12. Thecombination as recited in claim 9, wherein the peripheral edge of therigid member providing the mounting surface is beveled inwardly from thefront surface to the rear surface, and wherein the peripheral edge ofthe back plate defining the opening includes a lip tapered toward theopening.
 13. The combination as recited in claim 9, further comprising ashoulder on the rear surface of the rigid member adjacent the peripheraledge, the shoulder providing the mounting surface, and wherein theperipheral edge of the back plate defining the opening includes a lip ofreduced thickness adjacent the opening.
 14. A method for installing doorhardware onto a surface, the installation method comprising the stepsof: providing a bracket, the bracket including a rigid member having alongitudinal axis, a front surface, a substantially planar rear surfacefor engaging the support surface, and a peripheral edge extendingbetween and joining the front and rear surfaces, and a spirit bubblelevel disposed on the rigid member; positioning the rigid member on thesurface relative to a horizontal line or a vertical line, the levelhaving the bubble centered only when the level is horizontal orvertical; securing the bracket to the surface; providing a door hardwaremember, including a back plate for mounting door hardware components,the back plate defining an opening in a peripheral edge of the backplate corresponding to the shape of at least a portion of the peripheraledge of the rigid member; positioning the back plate against the surfacein contiguous relation with the bracket, wherein positioning the backplate comprises the step of inserting at least the portion of theperipheral edge of the rigid member into the opening in the back platesuch that at least a portion of the peripheral edge of the rigid memberprovides a mounting surface for the back plate when the rigid member issecured to the support surface for preventing movement of the back platerelative to the horizontal and the vertical line; and securing the backplate to the surface.